Convertible Top Hydraulic Hose: Service and Repair
FOLDING TOP HYDRAULIC CYLINDER HOSE REPLACEMENT - ALL
TOOLS REQUIRED
BO-47666 Hose Retainer Ring Installer
1. Place the folding top in the open position.
CAUTION: Refer to Eye Protection Caution in Service Precautions.
CAUTION: Refer to Folding Top Hydraulic Pressure Caution in Service Precautions.
CAUTION: Refer to Servicing Electrical Components Caution in Service Precautions.
NOTE: Refer to Cylinder Hoses Notice in Service Precautions.
2. Open the stowage compartment lid.
3. Disconnect the battery.
4. Place a protective cover over the rear compartment interior and the adjacent body panels.
5. Remove the body accessory compartment.
6. Remove the hydraulic pump noise covers.
7. Remove the 4 electrical connectors from the hydraulic pump solenoids as follows.
- Connector C 4 Green, to solenoid valve 4 (with Red and Green CKT).
- Connector C 3 Orange, to solenoid 3 (with a LT Blue CKT.)
- Solenoid Valve 2.
- Connector C 1 Green to solenoid valve 1 (with WHITE CKT).
- Connector C 2 Blue to solenoid valve 2. (with Dark BLUE CKT).
- Folding Top Pump with Motor (6).
8. Disconnect the 2 electrical connectors from the hydraulic pump.
9. Remove the nuts from the hydraulic pump bracket.
10. Lift the pump up and out of the storage compartment and set the pump on the protective covering.
11. Remove the reservoir filler plug.
12. Remove the hydraulic cylinder (1) from the mounting location. DO NOT remove the hoses from the cylinder at this time.
IMPORTANT: If you are replacing hoses from more than one cylinder, complete the procedure for one cylinder before you begin with another.
13. Remove the bolts from the pump manifold plate.
14. Carefully lift up on the manifold plate (1).
15. Locate the pair of cylinder hoses that need replacement.
IMPORTANT: Each cylinder is serviced by 2 hoses. In order to simplify the routing of the new hose, replace both hoses as a unit. Corresponding hose numbers are also stamped on the manifold plate to aid in identification.
16. For each pair of hoses being replaced, remove one hose by pulling straight up from the pump. Use a clean shop towel to control any hydraulic fluid leakage.
IMPORTANT: Remove the 2 hose connections one at a time. Repeat this entire procedure for the second hose.
17. Push the hose back through the manifold plate.
18. Remove the hose retaining ring.
19. Remove the hose from the manifold plate.
20. Push the manifold end of the new hose through the manifold plate.
21. Using the BO-47666, install a new hose-retaining ring (2) onto the hoses.
22. Push the assembly cone (2) over the end of the hose until the cone is fully seated.
23. Install the retaining ring (2) onto the assembly cone (1).
24. Using the BO-47666, push the retaining ring into place (2) onto the hose.
25. Push the hose into the manifold plate until the hose is fully seated (1).
26. Remove the assembly cone (1).
27. Repeat this procedure for the other hose in the pair.
28. Align the manifold plate bolt holes to the holes on the pump. This will ensure that the cylinder hoses are placed in the correct port.
29. Align the cylinder hoses into each port and push down until the hoses are seated properly in the hydraulic pump manifold.
30. Install the manifold plate bolts. DO NOT tighten.
31. Push down on the manifold plate (1) and verify that all of the cylinder hoses are seated properly.
NOTE: Refer to Fastener Notice in Service Precautions.
Tighten the bolts to 10 N.m (88 lb in).
32. Route the new hose set in the exact same way as the set being replaced.
IMPORTANT: Improper hose routing can lead to hose failure as a result of rubbing or pinching.
33. Depending on the hose set, you may have to remove and replace the following components:
IMPORTANT: Remove only one fastener at a time so that the amount of slack between fasteners can be exactly duplicated between the hose sets.
- The tie wraps
- The P-Clips
- The wire loom
- The conduit
34. Use a small flat-bladed tool (1) to release the retainer clip from one of the cylinder hoses.
IMPORTANT: Remove the 2 hose connections one at a time. Repeat this entire procedure for the second hose.
35. Remove the retainer clip (1).
36. Remove the cylinder hose (1). Use a clean shop towel to control any hydraulic fluid leakage.
IMPORTANT: After you have removed the cylinder hose, DO NOT move the cylinder rod. This will cause fluid to squirt out of the ports.
37. Remove the cylinder hose O-ring (1) from the cylinder.
38. Install a new O-ring (1) onto the cylinder hose (2).
39. Install the cylinder hose into the cylinder port (3). Press straight down on the hose until the hose is fully seated in the cylinder.
40. Install the cylinder hose retainer clip (1). Inspect the retainer clip to ensure that the clip is fully seated around the hose.
41. Repeat the replacement procedure for the second hose.
42. Install the appropriate hydraulic cylinder to the mounting location.
43. Install the reservoir filler plug (1).
44. Position the hydraulic pump to the correct mounting location.
45. Tighten the hydraulic pump bracket nuts.
Tighten the bolts to 18 N.m (13 lb ft).
46. Install the 2 electrical connectors from the hydraulic pump.
47. Install the 4 electrical connectors to the hydraulic pump solenoids as follows.
- Connector C 4 Green, to solenoid valve 4 (with Red and Green CKT).
- Connector C 3 Orange, to solenoid 3 (with a LT Blue CKT.)
- Solenoid Valve 2.
- Connector C 1 Green to solenoid valve 1 (with WHITE CKT).
- Connector C 2 Blue to solenoid valve 2. (with Dark BLUE CKT).
- Folding Top Pump with Motor (6).
48. Remove the protective covering.
49. Connect the battery.
50. Close the stowage compartment lid.
51. Bleed the hydraulic system. Refer to Folding Top Hydraulic System Bleeding Procedure.
52. Inspect the hydraulic system for fluid leaks.
53. Inspect the hydraulic system fluid level and add fluid as needed.
54. Inspect the folding top for proper operation.